Shielded HV Junction Box Assembly for Cable Shield Continuity
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Solution Overview
Problem
Existing high voltage junction boxes face challenges in maintaining shielding continuity between the shielding envelopes of cables and the box housing, while being complex and inflexible in manufacturing and maintenance, with a need for improved ergonomics, security, and durability.
Innovation Solution
The junction box is designed with integrated pass-through parts manufactured in one-piece with the housing structure, using insulating materials, and incorporates internal support parts and shielding elements to ensure electrical continuity and flexibility in design and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate pass-through parts are used to maintain shielding continuity, then shielding effectiveness is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the pass-through function directly into the housing structure by creating integrated openings with shielding flanges as part of the housing itself, eliminating the need for separate pass-through parts. This integration maintains shielding continuity while reducing assembly complexity and the number of components.
Solution Approach 2:
The housing structure is designed to serve multiple functions: it provides structural support, electrical insulation, and electromagnetic shielding simultaneously. The integrated pass-through openings with shielding flanges combine cable penetration and shielding continuity functions into a single structural element.
2Reliability
If metallic housing is used to provide electromagnetic shielding, then shielding effectiveness is improved, but ease of manufacture and adaptability decrease
Solution Approach 1:
The patent employs composite construction where a non-conductive housing material (such as plastic or composite) is combined with conductive shielding elements (metallic flanges or coatings) at critical locations. This composite approach provides electromagnetic shielding where needed while maintaining the manufacturing advantages of non-metallic materials.
Solution Approach 2:
Instead of making the entire housing metallic, the patent applies conductive shielding properties locally at the pass-through openings and critical areas where electromagnetic shielding is most needed. This localized approach maintains shielding effectiveness while preserving the ease of manufacture and design flexibility of non-metallic housing materials.
3Reliability
If complex shielding arrangements are implemented, then shielding continuity is maintained, but ease of repair and maintenance difficulty increase
Solution Approach 1:
By integrating the shielding function directly into the housing structure rather than using separate components, the patent eliminates the need for complex multi-part shielding assemblies. This integration simplifies maintenance as there are fewer parts to inspect, remove, or replace while maintaining shielding continuity.
Data Source
Figure 1
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AI summary
Present disclosure relates to a high voltage junction box for connections of shielded cables (59), comprising a conductive shielding shell (12,14) that includes at least one internal shield part (15,191) connected with cable shielding envelopes (592) of said cables. Its main housing (11) and its cable pass-through parts (111) are preferably a one-piece element, notably injected plastic, and the internal shield is connected with the cable shield (592) by metallic dowels (162) passing through the main housing (11). In an embodiment (1), the internal shield part is a local plate (15), that is connected by a pass-through plug or bolt to an external metallic shell that encases main housing (11) and closing cover (13). Another embodiment (1') comprises an internal full shielding shell, with two parts encased within the main housing and closing cover. Disclosure also relates to a method for assembling said junction box with the cable shielding envelopes.